The Engineer’s Guide to Custom Tubular Frames (Updated for 2025)

Last updated on July 14th, 2025 at 09:22 am

At the core of many industrial and commercial products lie tubular frames-structures designed to provide support, stability, and durability across a wide range of applications. Whether in medical devices, industrial machinery, or defense systems, these frames are the structural skeleton that ensures the strength and durability of your design. From machinery housings to protective enclosures, tubular frames are at the core of any well-engineered project.

Approved Sheet Metal (ASM) specializes in producing high-quality, custom tubular frames tailored to the unique requirements of various industries, leveraging decades of experience and a range of fabrication techniques to meet the most demanding specifications.

Common Types of Tubular Frames

Custom tubular frames are essential components across diverse industries, and each application has its own set of specific needs. Here are some of the most common types of tubular frames ASM fabricates:

• Structural Frames: Used to provide support for building structures and heavy-duty industrial equipment, these frames offer stability and load-bearing capacity.
• Machine Frames: These frames are crafted to house and support machinery, ensuring that all equipment remains securely mounted for operational efficiency.
• Enclosure Frames: Enclosures for electronic equipment, machinery, and sensitive devices rely on sturdy frames to ensure protection from environmental and mechanical damage.
• Chassis Frames: Found in the automotive and aerospace sectors, chassis frames form the backbone of vehicles, supporting the body, engine, and other vital components.
• Rack Frames: Commonly used in data centers, server rooms, and IT environments, rack frames organize and support hardware like servers and networking equipment.
• Display Frames: Frequently used in retail and exhibition spaces, these frames are designed to support signage, promotional materials, and other display units.
• Solar Panel Frames: These structures hold and support solar panels in installations ranging from residential to industrial, providing both stability and optimal positioning.
• Transport Frames: Built to provide stability during the transportation of goods, these frames are key to safe and secure logistics operations.

Materials and Components for Custom Frames

Tubular frames can be fabricated from a wide range of materials, including stainless steel, carbon steel, and aluminum. Each material comes with its own advantages in terms of strength, weight, and corrosion resistance. ASM frequently uses these materials to meet specific project demands:

• Stainless Steel: Known for its corrosion resistance and durability, this material is ideal for harsh environments and critical applications like medical devices and outdoor installations.
• Carbon Steel: Offering high strength at a lower cost, carbon steel is frequently chosen for industrial applications that require robust support structures.
• Aluminum: Lightweight and corrosion-resistant, aluminum is an excellent choice for applications where weight reduction is important, such as in aerospace or electronics.

In addition to these common materials, ASM also fabricates frames using extruded materials like Unistrut, provided the customer supplies the manufacturer and part number for sourcing. However, ASM strongly advises using materials and sizes that are readily available. Requests for uncommon or hard-to-source materials, such as metric tubing sizes not common in the U.S., can result in delays and increased costs.

ASM’s preferred suppliers for tubular frame components include:

• Online Metals
• Parker Steel (for metric tubing)
• Pierce Aluminum
• Stainless Tubular (for stainless steel tubing)

Advanced Fabrication Capabilities and Finishing Services

One of the key strengths of ASM is its comprehensive fabrication capabilities, which encompass tube laser cutting, forming, welding, hardware installation, and finishing services. By centralizing all these processes in-house, ASM ensures tighter control over quality, lead time, and cost.

Cosmetic considerations are an essential part of frame manufacturing, especially for applications like biomedical equipment where aesthetics matter. Engineers should clearly specify whether cosmetic welding and grinding are required, as some frames may need to be fully polished after welding to meet specific visual or functional standards.

For projects that involve special finishing requirements, such as plating or painting, ASM can handle most of the processes internally. However, for oversized frames, ASM may collaborate with specialized vendors to ensure that even large components receive the proper finish. These options are discussed early in the process to avoid any delays or unexpected costs.

Why Engineers Choose ASM for Custom Frames

At ASM, decades of experience in custom tubular frame fabrication equip us to handle projects of all sizes and complexities. Our team has seen it all-from small, precision-engineered frames to extremely large frames that require specialized treatment. For instance, we recently fabricated a 10-foot-long, 8-foot-tall, and 6-foot-wide biomedical frame, which required unique solutions to build, transport, and finish. This expertise and versatility allow us to take on challenges that other shops might shy away from, all while maintaining exceptional quality and delivery standards.

By working closely with our customers throughout the design and manufacturing process, ASM ensures that every frame meets the client’s exact specifications, from material selection to finishing touches.

Get Started with ASM Today

If you’re an engineer looking for a reliable partner to manufacture your custom tubular frame, Approved Sheet Metal is ready to assist. Our team will collaborate with you at every stage, from initial design review to on-time delivery, ensuring that your frame project is completed to your satisfaction.

Contact us today to request a quote and discuss your project in detail. Whether you need a small prototype run or a larger-scale production order, ASM has the expertise, technology, and experience to bring your vision to life.

Custom Sheet Metal Frame FAQ

What materials do you offer for custom tubular frames?

We fabricate tubular frames using stainless steel, carbon steel, and aluminum-each selected based on your project’s strength, weight, and corrosion resistance requirements. We also work with customer-specified extrusions like Unistrut, as long as the manufacturer and part number are provided.

Can you handle cosmetic requirements like polished welds or painted finishes?

Yes. If your application requires cosmetic welding, polished joints, or specialized finishes like powder coating or plating, we can handle it in-house or through trusted partners for oversized parts. Be sure to specify cosmetic requirements early in the process to avoid delays or additional cost.

What is the largest frame size you can fabricate?

We regularly build large custom frames-including one recent example that was 10 feet long, 8 feet tall, and 6 feet wide. If your frame requires special handling, transport, or finishing, we have the experience and equipment to manage it efficientl

What types of tubular frames do you commonly manufacture?

We produce a wide range of frame types including structural, machine, enclosure, chassis, rack, display, solar, and transport frames. Each frame is custom-engineered to match the mechanical and environmental demands of your application.

Can you assist with design for manufacturability (DFM)?

Absolutely. Our team collaborates closely with engineers to optimize frame designs for material availability, ease of fabrication, cost efficiency, and cosmetic outcomes. We’ll help you avoid sourcing delays and recommend adjustments to fit standard tubing sizes and finishes.